Method for packaging and handling fragile dicing blade

ABSTRACT

A reusable package and method suitable for storage and handling of a fragile dicing blade includes a rigid card having a smooth surface upon which the blade is placed. A flexible plastic film is placed over the blade and card surface and bonds to the surface through a molecular bonding action with sufficient bonding force for holding the disk in place on the card. With such a combination of card, blade and film, the blade is protected during storing, shipping and handling. Further, such a packaging method provides for repeated use of this non-adhesive package thereby increasing useful life of both the blade and package. Molecular bonding of the film to the card surface provides sufficient strength to hold the blade and to provide a hermetically sealed chamber within which the blade is positioned and stored. A package and handling for a fragile dicing blade and electronic components is described but application for components having stringent handling and storage requirements is appropriate.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Continuation-In-Part Application, and is relatedto application Ser. No. 07/996,612, filed Dec. 24, 1992 now abandoned,owned with the present invention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to the packaging and handling of sensitivecomponents of the electronics industry and in particular to fragiledicing blades. Diamond, cubic boron nitride, amber boron nitride andsilicon carbide blades are used for the cutting of hard brittlematerials such as those used in the manufacture of microelectroniccircuits and optical lenses that require small cutting blade widths. Theinvention addresses the handling, packaging, and storing of thesefragile dicing blades and sensitive electronic components.

2. Background Art

The manufacturing of diamond dicing blades used by the electronicsindustry is done by a handful of producers. To date, there are noestablished standards regarding size, tolerance or labeling, and by nomeans is there an established form of packaging for these fragile dicingblades.

The dicing blade is a relative of the abrasive grinding wheel used bymost machine shops and industrial manufacturers and the basis by whichthese tools work is similar. A major difference between these wheels orblades is the physical size. While there are many abrasive wheelmanufacturers, they do not have the ability to manufacture such afragile and delicate blade which is a reason for so few dicing blademanufacturers.

It is this handful of manufacturers that determines the packaging designfor the dicing blade based on feedback from their customers and theexperience gained through the trials, errors and testing of variouspackaging, handling and storing techniques. The result is that there area variety of packaging designs presently used. Each manufacturer uses adifferent design than their counterpart. Each manufacturer has itsadvantages and disadvantages in present packaging design but certainly,no standard or consistency has been established as of this writing.

As discussed, precision abrasive dicing blades are basically abrasivewheels used for grinding, slotting, and cut-off operations very commonin the machine shop environment but for major exceptions such asbrittleness and size. Dicing blades range in blade thickness from aslittle as two ten thousandths of an inch (0.0002") to as high as onequarter of an inch (0.2500"). Diameters range, typically, from two tofive inches. The finer thicknesses of 0.0008" to 0.0250" are extremelyfragile and demand great care in packaging and handling in order toprevent breakage of the dicing blade. They are often broken during thehandling of the blade prior to and following their use on the dicing sawor cutting machine. Improper handling during shipping, installation, andreuse results in broken, and thus unusable dicing blades.

Dicing blades are presently packaged and shipped in a variety of waysincluding rigid plastic or glass containers of various forms. In oneexample, of the rigid plastic container, a dicing blade or severaldicing blades are sandwiched between layers of foam, placed within thecontainer and sealed with a plastic cover which is taped to preventaccidental opening during handling and shipping. Identifying labels aregenerally affixed to the plastic cover, or lid. In this type ofpackaging, care must be taken to avoid pressing down on the top layer offoam during removal. Pressing down on the top foam can cause breakage ofthe dicing blade.

In certain dicing blade package designs, the blade is placed onto abottom rigid plastic or cardboard base having a raised center hubsimilar to a phonograph record resting on a turntable. The base is thenplaced into a box or container for further protection of the dicingblade. This bottom center hub is often a part of the package made ofrigid plastic material which is then affixed with a mating top cover.These packages take many stages and are generally awkward to handle.Other packages have bottom sections that have depressions to fit boththe inner and outer diameter of the dicing blade to prevent shiftingduring handling and transit. In certain similar embodiments, the hub ordepression is made a part of the container.

Consequently, packaging these fragile dicing blades has been difficultand users continue to demand support from the blade manufacturers forimprovements. Many packages utilize a flexible foam material to createan intimate contact with the dicing blade to prevent shifting within thecontainer. Other packaging such as those made by vacuum formed plasticswith top and bottom mating sections have raised hubs which rest on thetopmost dicing blade and adjust to the height of the dicing blade orstacked blades. Many dicing blades are placed between two plates ofglass or plastic held together with tape. Extreme care must be taken sothat the dicing blade does not slide toward the tapes and adhere to thetape resulting in blade breakage upon opening this type of packaging.

U.S. Pat. No. 4,819,412 issued to Sengewald discloses a process for themanufacture of packages made of prefabricated containers which aresubstantially dimensionally stable and have at a filling end and anoutwardly projecting flange edge on which a cover sheet is fixed bywelding, hot sealing or bonding. A thermoplastic sheet is applied to thecontainers to register a cover with the cover being separated alongweakening lines to form closed containers. The object of the inventionwas to facilitate packaging cups of thermoplastic sheet material closedby a cover sheet. Problems have occurred with similar packages when usedwith the fragile blades during the abrupt movements needed fordislodging the cover from the container.

U.S. Pat. No. 4,037,716 issued to Marks discloses a card holder for keysor similar items comprised of a thin card having a depressed regiontherein for receiving and containing the items and a pressureresealable, a partially adhesively-coated lid covers the depressedregion and is stripped or peeled back to expose the contained items. Thepresence of the adhesive creates further problems for the fragile diskfor even slight contact with the adhesive will cause the blade tofracture and become unusable.

U.S. Pat. No. 3,738,903 issued to Berwick et al. discloses an aperturedarticle of manufacture sealed in a plastic film envelope both along theperiphery and the edge of an aperture of the article. Opposite faces ofthe envelope, normally unconnected in the area of the aperture, arebrought together and heat sealed. The method of hermetically sealingopposite faces of a plastic film envelope along the edge of an apertureincludes clamping and heat sealing the edges. Focus in on protectivelyenclosing articles of manufacturer usually of a generally flatconfiguration in such a fashion as to leave the apertures open while atthe same time sealing not only about the outer periphery of the articlebut also along the edge of the aperture itself. The very permanentnature of the sealing process dictates that once the package is opened,it can no longer be used as originally intended. It is important in thehandling and storing of fragile blades that a package provide protectionof the blade but also that it be usable to meet blade use demands.

U.S. Pat. No. 3,456,784 issued to Sirago discloses a rigid, fluid tight,hand fracturable container for protecting o-rings and other small rubberor synthetic plastic parts from deterioration and deformation. Thepatent discloses a container in which a chamber is defined between twopanels which are sealed to one another in a fluid tight relationship.The container of the invention is adapted to protect a variety of sizesof circular precision seals from abrasion, deformation and deteriorationthrough contact with the ambient atmosphere. Access to the storedmaterial is achieved by fracturing the container thus permittingexposure and access. Again, reuse is not possible as is the case in manyof the packages in the prior art.

U.S. Pat. No. 4,741,119 issued to Baryla discloses a display board fordisplaying a sheet document behind a transparent window which relies onattraction caused by static electricity to hold the sheet documentbetween a backing board and the transparent window. Baryla '119discloses the use of a backing board made of dielectric material whichmay be any synthetic resin having a high dielectric constant. Asdescribed, preferably the board is a relatively thick and rigid plate ofacrylic resin having a smooth face for covering with a sheet oftransparent plastic film. Baryla '119 further discloses that it issufficient to rub the surface of the sheet document to charge itelectrostatically such that it clings to the face of the backing board,and the cover sheet of transparent plastic is caused to clingelectrostatically to the surface of the paper document, and cling inmost instances, to marginal surface portions of the backing board.Although such a device and method is useful for displaying a sheetdocument, such in not the case for a fragile dicing blade. Fragiledicing blades are typically conductive. Static clinging of theconductive blade is therefore not possible as might be suggestive in thedisplay device of Baryla '119. Further, the clinging forces developed bythe static charges are typically orders of magnitude below what isrequired to hold items such as a fragile dicing blade in place. Aclinging force unavailable through static cling is needed for a packageneeded in the industry. The teachings in the display of paper sheetdocuments using static cling techniques is not where one would look tosolve the problems associated with the handling, packaging, and storingof fragile dicing blades.

Further, the teachings in the display arts in general do not solve thespecific problems associated with handling the fragile blades. By way ofexample, U.S. Pat. No. 3,670,434 to Shibata et al. discloses an adhesivesheet device for mounting photographs and other display items in albumswhich includes providing a relatively thick backing sheet and thin filmof pressure-sensitive adhesive coating on one surface of the sheet. Acover sheet is disengageably adhered to the coated surface of thebacking sheet for insertion of an item beneath the cover sheet for clearviewing. As described earlier, the adhesive material would be harmful tothe blade and cause breakage during use.

SUMMARY OF INVENTION

Faced with the needs in the industry as earlier herein described, thepresent invention provides a reusable package for the storing, shipping,and handling of disks such as the fragile dicing blades used in theelectronics industry. It is typical in the industry for a blade to bedamaged when received by the user. Such damage occurs during theshipment because of the brittle nature of the abrasive dicing blade. Theuser often damages the blade beyond use in a first step of removing theblade from its package. Typical packages may protect the blade forshipment but will not protect the blade during removal from that packageand handling through continued use and reuse of the blade. In addition,because the blades typically do not have their specifications affixed tothe blade itself but to their packaging, it becomes important to providea package that can be repeatedly used without damage to the package andwithout deformation and thus damage to the fragile blade.

It is therefore an object of this invention to provide a package thatwill protect the fragile blades and sensitive components duringshipping. It is also an object to provide a package that can be reused amultiplicity of times without damage to the package or to the blade. Itis yet another object to provide a method for handling fragile dicingblades and the sensitive components in such a way that theiridentification is maintained throughout their use and provide access toa new blade or used blades that is safe and decisive for the user. Anembodiment of the invention disclosed specifically addresses the storageand handling of fragile abrasive blades used in cutting silicon andother hard electronic materials. However, an extension to the handlingof other products is anticipated for ease in handling and multiple usewithout damage to the product or to the package. It is yet anotherobject of the invention to provide a reusable package for componentssensitive to static charges, wherein such static charges typicallydamage or destroy the component. Further, it is an object to providesuch a package that hermetically seals the component for storage andhandling within and outside clean room conditions.

The dicing blade, as stated earlier, is fragile; and within the range ofdicing blades, there are some more fragile than others, specifically thedicing blades with a thickness range of 0.0008 to 0.0020 inches. Theseblades have a frequent breakage problem. Considering the average cost ofthese blades at this writing is about $25.00 each, it is a major concernto the end user to safely get these blades to production and store themsafely when not in use. It is therefore a further object of theinvention to provide a reusable non-adhesive package with sufficientstrength for holding a fragile blade therein and further to provide anairtight seal for such storage.

With such needs identified, manufacturers are constantly attempting newpackage designs to address these issues, and until the presentinvention, no package has been able to satisfactorily solve theseproblems.

With such in mind, a method for storing and handling a fragile dicingblade comprises the steps of providing a substantially flat card havinga flat smooth surface sufficiently smooth for permitting a fragile bladeto be slidably moved across the surface, the surface sized to receivethe fragile dicing blade, placing the fragile dicing blade onto thesmooth surface, and placing a flexible plasticized film onto the smoothsurface thus covering the blade, the film having a first outer surfaceand a second contact surface, the film second contact surface bonding tothe card surface through a molecular bonding sufficient for holding thefragile blade between the contact surface and the card surface. Thebonding force between the film and card is such to provide a hermeticseal around the blade when the film is pressed against the card surfaceat portions of the card surrounding the blade, thereby forming anairtight chamber.

In an alternate embodiment, pockets within the card and the film incombination form the airtight chamber, wherein sensitive workpieces arestored.

By affixing a tab to the card, indicia is added to the tab thatprovides, by way of example, the disk specifications. With a transparentfilm, indicia containing generic information about the disk andinformation about the recommended handling of the disk, especially inthe case of fragile dicing blades placed on the card is in clear viewalong with information contained on the blade itself.

By providing a notch along an edge portion of the card and extending thefilm over the notch, the film is easily accessible and pulled back fromits clinging position when access to the disk is desired. In addition,by affixing an edge of the film to an edge of the card, the film can bepeeled back to expose the disk and remain with the card.

The method permits the storage, removal and reuse of the package andblade a multiplicity of times without damage to the package or theblade.

BRIEF DESCRIPTION OF DRAWINGS

A preferred and alternate embodiments of the present invention isdescribed by way of example with reference to the accompanying drawingsin which:

FIG. 1 is a front plan view of a preferred embodiment of the presentinvention;

FIG. 2 is a partial cross-sectional view of the embodiment of FIG. 1through a central portion thereof;

FIG. 3 is a perspective view of the embodiment of FIG. 1 illustratingflexible film peeled away from a card surface;

FIG. 4 is a front plan view of an alternate embodiment of the presentinvention;

FIG. 5 is a partial cross-sectional view passing through section V--V asillustrated in FIG. 4;

FIG. 6 is a partial cross-sectional view passing through section VI--VIas illustrated in FIG. 5;

FIG. 7 is a partial cross-sectional view as illustrated in V--V of FIG.4 further illustrating work pieces within air tight chambers formed bycard pockets and flexible film in a hermetic seal combination;

FIG. 8 is a partial side view of a film and card surface functionallyillustrating a contact surface for use in tests and measurements of peelstrength, bonding, or clinging forces;

FIG. 9 is a graph illustrating a load-elongation relationship for a filmmaterial of the present invention; and

FIG. 10 is a graph illustrating a load-elongation relationship for astatic cling sample material.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

A preferred embodiment of the present invention, a reusable package 10suitable for storing a fragile dicing blade or disk 12 is illustratedwith reference to FIGS. 1 through 3. In the present invention, thepackage 10 comprises a card 14 having a smooth surface 16. In thepreferred embodiment of the present invention, the card 14 is generallyrectangular in shape and comprises a central portion 18 within a cardmarginal portion 20 around the central portion 18 and generally aboutthe periphery of the card 14. The central portion 18 is dimensioned toreceive the blade 12. It is anticipated that various size cards 14 willbe used to hold the various sized blades 12 currently in use within theindustry as specifically addressed herein for dicing blades or otherdisk styled pieces requiring special handling and care.

In the embodiment illustrated with reference to FIGS. 1, 2 and 3, atransparent flexible film 22 is used. The film 22 is sized to fit thecard 4 for covering the card marginal and central portions 18, 20. Witha blade 12 placed within the card central portion 18, the film 22 coversthe marginal portion 20 sufficiently for providing a molecular bondingforce to bond the film 22 to the smooth surface 16 and thus hold theblade 12 in place within the card central portion 18. With reference toFIG. 2, the blade 12 is couched within the central portion 18 as thefilm 22 covers the marginal portions 20 of the card smooth surface 16. Afilm edge 24 is affixed to a cooperating card edge 20 to maintaincommunication between the card and film. Thus, the film 22 remains withthe card 14 when not in use, and provides a convenient mechanism whenhandling and storing the disk 12.

In one embodiment, a tab 28 is integrally formed with the card 12. Byway of example, the tab 28 is used for indicia 30 to provide informationabout the disk 12 being stored in that specific package 10. Otherindicia locations throughout the card surface 16 are used to provideinformation about the handling 32 and product manufacturer 34, hereinpresented by way of example. Further, the use of a transparent film 22,although not necessary for storage, permits indicia to be imprinteddirectly onto the card smooth surface 16 and be clearly visible tousers. A plurality of indicia combinations and indicia locations areanticipated to suit the needs of the specific user or blade 12.

Before placing the blade 12 onto the card 14, the film 22 is peeled backas illustrated with reference to FIG. 3. By locating a notch 36 at amarginal portion site 40, the film 22 is easily accessed or secured andpeeled back so as to expose the card central portion 18 for access tothe blade during blade removal or replacement steps. By keeping thesmooth surface 16 an the film contact surface 23 clean, the placementand removal of the disk 12 can be executed a multiplicity of timeswithout damage to the blade 12 or the package 10.

Further, by maintaining a clean smooth surface 16, the blade 12 can beslid from the central portion 18 to past the marginal portion 20 and offthe card smooth surface 16 onto an appropriate work surface (not shown)employed by the user. In addition, maintaining a clean smooth surface 16and clean film contact surface 23 provides an optimum peel strength orbonding force between the surfaces 16, 23. Although not required,pressing on the film 22 along a film top surface 21 at a film portioncommunicating with the card marginal portion 20, additional bondingforce is achieved for sufficiently holding the blade 12 in place withinthe central portion 18 where is had been placed during handling. Thepressing assures that a bonding force between the card surface 16 at thecard marginal portion 20, wherein the surface 16 in contact with thefilm contact surface 23, provides a hermetic seal around the blade 12for alternate embodiments where airtight sealing of the blade 12 orother components is needed.

Again with reference to FIG. 2, the film contact surface 23 forms ahermetic seal with the card surface 16 and when passing around thecentral portion 18 forms an air tight chamber 42 for the blade 12 orother workpiece being stored within the package 10. Providing an airtight chamber 42 as described permits a blade 12 to be packaged within a"clean room" environment, transported through a "contaminated air"environment to another clean room environment where it is unpacked. Sucha procedure will be more appreciated for workpieces such as electroniccomponents whose handling requires the strictest of clean roomconditions. An alternate embodiment of the package 100 focuses on thepackaging of an electronic component by way of example with reference toFIGS. 4-7.

The package 100, as illustrated with reference to FIG. 4, comprises acard 110 having a plurality of pockets 112 positioned within a cardcentral portion 114. The pockets 112 are dimensioned for receiving aworkpiece 116, an electrical component such as a die as will be herein,by way of example, described with reference to FIG. 7. It is anticipatedthat various numbers and sizes of pockets will be formed within the cardcentral portion to accommodate the various components suited to suchpackaging. The example illustrated with reference to the embodimentaddressed is prepared for a die having a dimension of approximately 10mmsquare by 0.5mm thick.

With reference to FIG. 5, the flexible film 118 removably bonds with thecard surface 120, through a molecular bonding, along card marginalportion 122 forming a hermetic seal, as was earlier discussed withreference to the package 10 of FIGS. 1-3. In addition, a seal is formedat surface contact locations 124 around each pocket 112. Air istherefore trapped within each chamber 126 formed by the combination ofpocket 112 and film 118. As earlier described, it is now possible topackage a component 116 within a clean room environment and transportthe package 100 with the component 116 through a dirty environment toanother clean room for unpacking while maintaining the component 116within a specified clean room condition. Further, like the embodiment 10earlier described, the alternate package 100 is reusable, does notrequire adhesives that can damage the package 100 and the component 116,and provides easy access to the workpiece/component 116.

Further by way of example, in semiconductor manufacturing, typicalproblems resulting from static electricity are attraction ofcontamination, and degradation or destruction of components due toelectrostatic discharge. Static-caused contamination problems are seenat practically every stage of the manufacturing process from the artworkpreparation and masking stages to final packaging. Not only do the toolsused, work surfaces, and surrounding materials become charged, but thecontaminated particles themselves also become charged and attract othercontaminants. By providing the package 10, 100, as described, employingan antistatic vinyl film, damaging static charge is eliminated.

As illustrated with reference to FIG. 6, one embodiment of the presentinvention comprises a thin film of vinyl 118 coated onto the cardsurface 120 for contacting the film 118 which in one embodimentcomprises a vinyl material similar to that of the film 128. However, avariety of surfaces are appropriate and typically include non-poroussmooth surfaces to allow for molecular bonding and a hermetic sealbetween the card surface and film contact surface. Again with referenceto FIG. 5, chambers 126 are formed by the combination of card pocket 112and film 118 and with such a chamber 126, workpieces 116 are storedtherein as illustrated with reference to FIG. 7. As earlier describedwith reference to FIGS. 1-3, by using a transparent film material, theworkpiece 116, and indicia 130 placed on the card surface at appropriatelocations 132, 133, by way of example, permit convenience in thehandling of the package 100 and workpiece 116. Various tests andmeasurements were made during the development of the present invention.Initially, studies were completed for the purpose of determining therange of holding power, peel strength, or bonding force of the plasticfilm 22 used in the present embodiment. Three different thicknessplastic thin films, which bond to a smooth surface 16, through molecularbonding were tested to determine their holding power. The specimens were12 mils, 7 mils and 4 mils thick. Measurements of peel strength weremade after one, ten and twenty three peels. Apparatus was used asdescribed in ASTM D-4649 Section A3.3 along with an INSTRON Model No.1122 for testing samples. The range of holding power for the films wasdetermined. It was concluded that a film thickness of a few mills wassufficient to support a blade 12 such as the fragile dicing bladesherein described. For the typical number of times that a blade isremoved and replaced in its package, a wide range of film thicknesses isanticipated. As the film thickness increases, increased protection ofthe blade 12 is realized but it becomes more difficult to ensure thatthe film 22 sufficiently clings to the card marginal portions 20. Thepreferred embodiment of the present invention uses a film thickness ofless than ten mils for use with blades ranging in thickness from a tenthof a mill to approximately six mils. It is anticipated that variousthickness films will be used as well as a variety of thickness disks.

Within the background section of this specification, it was stated thatreliance on static cling between a film and board or card surface as isused for displaying photographs and paper products was not appropriatefor storing fragile dicing blades. In fact, even if the typical dicingblade was not electrically conductive, the present invention requiresbonding forces that are orders of magnitude greater than can be achievedusing static charges and therefore the disclosure addressed in thebackground section could not satisfy the needs presented herein.Further, achieving a hermetic seal would be difficult if not impossiblegiven the nature of the static clinging process.

It is not the intent nor within the scope of this specification to fullydescribe physical phenomenon but to point out distinguishingcharacteristics and quantify to some extent terms used within thespecification and claims which distinguish over prior art.

To address holding forces more precisely, first consider the fact thatadhesion has different definitions in different disciplines according tothe McGraw-Hill, Inc. Dictionary of Scientific and Technical Terms, 5thEdition. As herein addressed, there is a distinction between mechanicaladhesion such as a clinging force from static friction and a physicaladhesion resulting from intermolecular forces causing molecular bonding.The forces between the film contact surface 23 and the card smoothsurface 16 from such molecular bonding are sufficient to hold the blade12 between the film 22 and the card surface 16. Static cling forces arenot.

To quantify such a distinction, tests were run to distinguish betweensuch forces and to support the claimed invention which calls for, by wayof example, clinging with sufficient force for holding the blade 12between the film 12 and the card surface 16.

With reference to FIG. 8, load measurements were made for a vinylplastic film used in the preferred embodiment of the invention and asample cut from a calendar packaging material presumed to be a polyvinylacetate having static cling characteristics suggested in the prior art.The calendar was supplied by Keith Clark Co. of Sidney, N.Y. and thevinyl was representative of that typically supplied by Molco, Inc. ofWaymart, Pa. The tests and measurements were provided by E. Dow Whitney,Ph.D. from the University of Florida, Department of Materials Scienceand Engineering, Gainesville, Fla.

The results from the tests and measurements are summarized in Table 1.The x-series values in the left column represent the vinyl material usedin the present invention, while the y-series values are for the staticclinging material typically found in display products referred to in theprior art and represented by the calendar sample addressed above. Fivesamples were tested from each of these groups, with each sample beingtested three times. Samples 1a, 1b, and 1c, for example, represent threeconsecutive trials of the same sample. The specimens 200 were preparedidentically in form of rectangular lap joints 210, 0.5 inches wide and3.5 inches in length, with a 2.5 inch overlap 212 to define a bondedarea as illustrated with reference to FIG. 8. The tests were performedon an Instron 1120 Tensiometer using a 3.0 gauge length and a constant1.0 inch per meter stroke rate to measure a "clinging force" 214 forpulling the samples apart. Test conditions were identical for bothmaterials, except that a smaller load cell was substituted for themeasurement of the load values (for accuracy) for the y-series (staticcling) samples.

                  TABLE 1                                                         ______________________________________                                        TEST AND MEASUREMENT RESULTS                                                               Load (pounds)                                                    Sample         x-series                                                                              y-series                                               ______________________________________                                        1a             2.33    0.001519                                               1b             2.28    0.001732                                               1c             2.66    0.003840                                               2a             2.57    0.001171                                               2b             2.60    0.001645                                               2c             2.64    0.002274                                               3a             2.83    0.003298                                               3b             2.67    0.004646                                               3c             2.59    0.006149                                               4a             2.67    0.006214                                               4b             2.76    0.009458                                               4c             2.43    0.004148                                               5a             2.79    0.002882                                               5b             2.60    0.006675                                               5c             2.65    0.004132                                               ______________________________________                                    

The first one should observe when comparing the values of Table 1 isthat there is a three orders of magnitude difference between the loadssupported by the x-series and y-series samples. The strength of thex-series lap joints is far greater than what would be expected due tostatic cling. The x-series lap joint provides "sufficient force forholding a blade between the film and the card surface" of the presentinvention. In fact, the material in the lap joint of the y-series,static cling sample, is incapable of sustaining a level of static chargethat would be required to explain the high loads, and sufficient bondingforces, needed in the present invention.

Further, FIGS. 9 and 10, are included by way of example to depict loadand elongation behavior for a representative sample of each material.FIG. 9 is a representative load-elongation curve 216 for one of thex-series samples used in the packages 10, 100 of the present invention.The first part of the curve 218 is roughly linear, and corresponds toelastic deformation of the plastic half of the lap joint. The point 220in the curve where the first jagged edges appear corresponds to theonset of slip. From this point 220 on, the material alternates betweenelastic deformation of the plastic and yielding (a reduction in overlaparea) in the joint area. FIG. 10 is a representative load-elongationcurve 222 for one of the y-series, static cling, lap joints. In contrastto the x-series samples, the applied stress in this case is distributedover the entire overlap length 212. As a result, as soon as the joint isstress, slippage begins to occur, resulting in a reduction of overlaparea 212 because the stress is uniformly distributed and the joint issubjected to a constant strain rate, the supported load undergoes aroughly linear decrease until failure as further illustrated withreference to the graph of FIG. 10. In other words, the bonding mechanismas well as the magnitude of bonding forces is substantially different, ateaching away from the prior art static clinging methods earlierdescribed with reference to displaying photographs.

While a specific embodiment of the invention has been described indetail herein above, it is to be understood that various modificationsmay be made from the specific details described herein above withoutdeparting from the spirit and scope of the invention as set forth in theappended claims.

Having now described the invention, the construction, the operation anduse of preferred embodiments thereof, and the advantageous new anduseful results obtained thereby, the new and useful constructions,methods of use, and reasonable mechanical equivalents thereof obvious tothose skilled in the art, are set forth in the appended claims.

What is claimed is:
 1. A method for storing and handling a fragiledicing blade useful in dicing semiconductor devices, the methodcomprising the steps of:providing a substantially flat card having aflat smooth surface sufficiently smooth for permitting a fragile bladeto be slidably moved across the surface, the surface sized to receivethe fragile dicing blade; placing the fragile dicing blade onto thesmooth surface; and placing a flexible plasticized film onto the smoothsurface thus covering the blade, the film having a first outer surfaceand a second contact surface, the film second contact surface bonding tothe card surface through a molecular bonding sufficient for holding thefragile blade between the contact surface and the card surface.
 2. Themethod as recited in claim 1, further comprising the steps of:extendingthe film over a notch provided along an edge of the card, the notchproviding access to the film for peeling back the film from the cardthus uncovering the fragile dicing blade; peeling back the film forexposing the dicing blade; and sliding the fragile dicing blade from thecard smooth surface.
 3. The method as recited in claim 1, furthercomprising the steps of:providing a card central portion sufficient forreceiving the blade; and providing a card marginal portion extendingaround the blade when placed within the central portion for providingthe molecular bonding between the film contact surface and the portionof the card surface within the marginal portion for holding the fragiledicing blade in a position within the central portion.
 4. The method asrecited in claim 1, wherein the card further comprises a tab extendingfrom a peripheral portion of the card, the tab for handling the card andplacing indicia thereupon.
 5. The method as recited in claim 1, furthercomprising the step of providing the card with a rigidity sufficient forholding the blade in a surface plane of the card.
 6. The method asrecited in claim 1, further comprising the steps of:providing an edge onsaid card for affixing a portion of said film to said edge; and couplingthe film to the card by affixing a film edge to the card edge.
 7. Amethod for storing and handling a fragile dicing blade useful in dicingsemiconductor devices, the method comprising the steps of:providing acard having at least one flat smooth surface, the surface sufficientlysmooth for permitting a fragile dicing blade to be slidably moved acrossthe surface; placing a plasticized film having a peel strength forbonding to the card surface, the peel strength resulting from amolecular bonding sufficient for holding a dicing blade on the surfacefor a multiplicity of film peeling steps, the film having a top surfaceand an opposing bottom surface, the bottom surface for clinging to thecard smooth surface; peeling the film from the card surface for exposinga portion of the card sufficient for receiving the dicing blade; placingthe fragile dicing blade onto the smooth surface; sliding the bladeacross the smooth surface to within the blade receiving portion; placingthe film onto the card surface for covering the blade; and pressing onthe film top surface for providing sufficient bonding of the film bottomsurface with the card smooth surface for holding the blade within apocket formed between the card surface and film bottom surface.
 8. Themethod as recited in claim 7, further comprising the steps of repeatingthe film peeling, blade placing, film placing and film pressing steps amultiplicity of times for reusing of the card, film and blade.
 9. Themethod as recited in claim 7, wherein the film pressing step issufficient for enhancing the molecular bonding between the film contactsurface and the card smooth surface, the molecular bond providing thebonding sufficient to hold the blade between the film and card surfaces.10. The method as recited in claim 7, wherein the film pressing step issufficient for providing a hermetic seal between the film contactsurface and the card smooth surface, the seal providing an air tightchamber within which the blade is positioned.
 11. The method as recitedin claim 7, further comprising the step of extending the film over acard edge portion for holding the film during the peeling step.
 12. Themethod as recited in claim 7, further comprising the step of maintainingthe card in a substantially rigid configuration for holding the bladewithin a plane sufficient preventing fracture of the blade.
 13. Themethod as recited in claim 7, wherein the plasticized film comprises ananti-static PVC film.
 14. The method as recited in claim 7, wherein theblade is electrically conductive.
 15. A method for storing and handlinga fragile dicing blade while reducing the likelihood of breakage of theblade, the method comprising the steps of:providing a card having asmooth flat surface, the surface sufficiently smooth for permitting afragile dicing blade to be slidably moved across the surface, the cardhaving a central portion and a marginal portion, the central portiondimensioned to receive the fragile dicing blade, the card sufficientrigid for limiting bending of the blade while preventing blade fracture;placing a fragile dicing blade on the surface within the card centralportion; placing a flexible film over the card surface for covering theblade, the film dimensioned to cover the card central and marginalportions, the film further having a peel strength resulting from amolecular bonding for adhering to the card smooth surface withsufficient bonding force for holding the blade within the centralportion; pressing on film portions communicating with marginal cardportions for enhancing the bonding force between the film and the cardmarginal portion surfaces; storing the card containing the fragiledicing blade; peeling back the film from the surface for exposing theblade; removing and handling the dicing blade by sliding the bladeacross the card smooth surface to a position wherein the blade isseparated from the card surface; using the blade; placing the blade backonto the card surface; sliding the blade across the surface to withinthe card central portion; overlaying the film onto the card surface, thefilm covering the blade; pressing on film portions communicating withmarginal card portions for enhancing the bonding force between the filmand the card marginal portion surfaces, thereby securing the bladewithin the card central portion, the film bonding to the surface of thecard marginal portions surrounding the blade; and storing the cardcontaining the fragile dicing blade for reuse.
 16. The method as recitedin claim 15, wherein the steps of pressing on the film along marginalcard portions form a hermetic seal within the card marginal portionbetween the card smooth surface and the film, thereby placing the bladewithin an airtight chamber formed within the card central portion. 17.The method as recited in claim 15, wherein the film is transparent. 18.The method as recited in claim 15, wherein the card central portioncomprises a pocket for receiving the blade, the pocket and film incombination defining a chamber for placing the blade therein andremoving the blade, the combination permitting a multiplicity of theplacing and removing steps.
 19. The method as recited in claim 18,wherein the film pressing step form a hermetically sealed chamber.
 20. Amethod for storing a fragile dicing blade comprising the stepsof:providing a card sufficiently rigid for protectively supporting afragile dicing blade thereagainst, the card having a smooth surface forreceiving the blade, the surface sufficient for bonding with a flexiblefilm in a molecular bonding relationship, the surface sufficientlysmooth for permitting the fragile dicing blade to be slidably movedacross the surface, further the card surface having a central portiondimensioned for receiving the blade and a marginal portion around thecentral portion; placing a fragile dicing blade onto the card surfacewithin the central portion by sliding the blade across the card smoothsurface; and placing a plasticized flexible film over the card surface,the film dimensioned for covering the central and marginal portions, thefilm having a contact surface and an opposing top surface, the contactsurface bonding to the marginal portion through a molecular bonding withsufficient force for holding the blade within a fixed position withinthe central portion for storing the blade.
 21. The method as recited inclaim 20, further comprising the steps of a film contact surface portioncommunicating with the card surface marginal portion for enhancing themolecular bonding between the film contact surface and the card marginalsurface, the molecular bonding sufficient for providing a hermetic sealaround the central portion thereby forming an airtight chamber withinwhich the blade is positioned.
 22. The method as recited in claim 20,further comprising the step of hingedly affixing an edge of the filmwith a corresponding edge of the card for maintaining at least partialcontact between the card and the film.
 23. The method as recited inclaim 20, further comprising the step of cleaning said smooth surfaceprior to blade placing step, the surface sufficiently cleaned forproviding uniform clinging force for the film contact surface with thecard smooth surface.
 24. The method as recited in claim 20, wherein acavity is formed within the card central surface portion, the cavitydimensioned for receiving a blade, further, the card smooth surface isformed from a vinyl plastic layer formed onto the surfaced of the card.25. The method as recited in claim 24, wherein the film comprises avinyl plastic film.